This article supersedes TSB'S 09-12-2 and 07-21-4 to direct repairs to the Workshop Manual (WSM) Turbocharger Reconditioning procedure added to the online WSM and updates to the pinpoint test (PPT) in the Powertrain Controls/Emission Diagnostic (PC/ED) manual.

ISSUE:

Some 2003-2007 F-Super Duty, 2004-2007 F-650/750, 2003-2005 Excursion and 2004-2009 Econoline vehicles equipped with a 6.0L diesel engine may exhibit any one, or a combination of the following concerns: lack of power, white/black smoke or a surge.

On 2003-2007 F-Super Duty, 2003-2005 Excursion, and 2004-2009 Econoline these concerns may or may not be accompanied by any one, or a combination, of the following diagnostic trouble codes (DTCs): P0238, P0299, P0404, P0478, P2262 and/or P2263. These concerns and/or DTCs could be a result of coking deposits inside the turbocharger.

On 2004-2007 F-Super Duty 650-750, these concerns may or may not be accompanied with the following DTCs: 261, 342, 343, 353, 354 and/or 361. These concerns and/or DTCs could be a result of coking deposits inside the turbocharger.

For F-Super Duty, Excursion, E-Series vehicles built on or before 9/29/2003, follow PPT KA in the PC/ED manual diagnostics. If the PPT in the PC/ED manual diagnostics leads to turbocharger replacement, use the Turbocharger Inspection Procedure first to check for internal turbocharger oil leaks. Then, determine if the turbocharger can be repaired with a center housing rotating assembly (CHRA) replacement or if it can be cleaned instead of replacing the entire turbocharger following the turbocharger reconditioning service procedure.

For F-Super Duty, Excursion, and E-Series vehicles built on or after 9/30/2003, perform the Powertrain Air Management Turbo Boost test and VVT test with IDS. Use of the VPS tool 418-626 along with IDS/VMM is required. Tool 418-626 was shipped in kit TKIT-2007VP-F and TKIT-2007TV-F. Dealers should have received one or the other of these two kits.

Refer to the updated online WSM, Section 303-04D: for diagnosis, testing and reconditioning of the turbocharger assembly.

For F-Super Duty 650-750 vehicles, refer to the updated online WSM, Section 303-04B: for diagnosis, testing and reconditioning of the turbocharger assembly.

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty CoverageIMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATION

DESCRIPTION

TIME

MT091605

Use SLTS Operations If Available; Claim Additional Diagnosis Or Labor Performed As Actual Time